Mars ISRU for Production of Mission Critical Consumables ... · Mars ISRU for Production of Mission Critical Consumables – Options, Recent Studies, and Current State of the Art

American Institute of Aeronautics and Astronautics

1

Mars ISRU for Production of Mission Critical Consumables

– Options, Recent Studies, and Current State of the Art

Gerald B. Sanders1, Aaron Paz2, Lara Oryshchyn3, and Koorosh Araghi4

NASA, Johnson Space Center, Houston, TX, 77058, USA

Anthony C. Muscatello5

NASA Glenn Research Center Cleveland, OH, 44135, USA

Diane L. Linne6, and Julie E. Kleinhenz7

NASA Kennedy Space Center, FL, 32899, USA

and

Todd Peters8

Jacobs Engineering, Houston, TX, 77598, USA

In 1978, a ground breaking paper titled, “Feasibility of Rocket Propellant Production on Mars” by Ash, Dowler,

and Varsi discussed how ascent propellants could be manufactured on the Mars surface from carbon dioxide

collected from the atmosphere to reduce launch mass. Since then, the concept of making mission critical

consumables such as propellants, fuel cell reactants, and life support consumables from local resources, commonly

known as In-Situ Resource Utilization (ISRU), for robotic and human missions to Mars has been studied many

times. In the late 1990’s, NASA initiated a series of Mars Human Design Reference Missions (DRMs), the first of

which was released in 1997. These studies primarily focused on evaluating the impact of making propellants on

Mars for crew ascent to Mars orbit, but creating large caches of life support consumables (water & oxygen) as a

backup for regenerative life support systems for long-duration surface stays (>500 days) was also considered in

Mars DRM 3.0. Until science data from the Mars Odyssey orbiter and subsequent robotic missions revealed that

water may be widely accessable across the surface of Mars, prior Mars ISRU studies were limited to processing

Mars atmospheric resources (carbon dioxide, nitrogen, argon, oxygen, and water vapor). In December 2007, NASA

completed the Mars Human Design Reference Architecture (DRA) 5.0 study which considered water on Mars as a

potential resource for the first time in a human mission architecture. While knowledge of both water resources on

Mars and the hardware required to excavate and extract the water were very preliminary, the study concluded that a

significant reduction in mass and significant enhancements to the mission architecture were possible if Mars water

resources were utilized. Two subsequent Mars ISRU studies aimed at reexamining ISRU technologies, processing

options, and advancements in the state-of-the-art since 2007 and to better understand the volume and packaging

associated with Mars ISRU systems further substantiated the preliminary results from the Mars DRA 5.0 study.

This paper will provide an overview of Mars ISRU consumable production options, the analyses, results, and

conclusions from the Mars DRA 5.0 (2007), Mars Collaborative (2013), and Mars ISRU Payload for the Supersonic

Retro Propulsion (2014) mission studies, and the current state-of-the-art of Mars ISRU technologies and systems.

The paper will also briefly discuss the mission architectural implications associated with Mars resource and ISRU

processing options.

1 ISRU Chief Engineering, Energy Conversion Systems Branch, EP3, AIAA Member. 2 ISRU Engineer, Energy Conversion Systems Branch, EP3, AIAA Member. 3 Engineer, Energy Conversion Systems Branch, EP3, AIAA Member. 4 Fuel Cell and Electrolysis Technology Manager /PI, Energy Conversion System Branch, EP3, AIAA Member. 5 Chemist, Applied Science, UB-R3,non AIAA member. 6 Senior Research Engineer, Propulsion Division, MS 301-3, AIAA Associate Fellow. 7 Research Engineer, Propulsion Division, MS 301-3, AIAA Senior Member. 8 Manager, Enery Systems Test Area, EP6, non AIAA Member.

https://ntrs.nasa.gov/search.jsp?R=20150016009 2020-06-09T13:19:45+00:00Z

Pg 1G. Sanders, (281) 483-9066, [email protected]

Mars ISRU for Production of Mission Critical Consumables

– Options, Recent Studies, and Current State of the Art

G. B. Sanders1, A. Paz1, L. Oryshchyn1, K. Araghi1, A. Muscatello2, D. Linne3, J. Kleinhenz3, and T. Peters4

1. NASA Johnson Space Center, Houston, TX,

2. NASA Kennedy Space Center, KSC, FL

3. NASA Glenn Research Center, Cleveland, OH

4. Jacobs Engineering, Houston, TSX

Sept. 1st, 2015

AIAA Space 2015 Conference, Pasadena, CA


Mars ISRU Mission Studies

Past Mars Studies with ISRU (DRM 1 to 4)– Only considered atmospheric resources were available (CO2, N2, Ar)

– Evaluated two propellant production options• Make Oxygen (O2) only and bring fuel from Earth

• Make O2 and methane (CH4) with hydrogen (H2) brought from Earth

– Produced various amounts of life support consumables as backup• Ex. DRM 3: 4500 kg of O2; 3900 kg of N2 ; 23,200 kg of water (H2O)

– ISRU considered only after performing non-ISRU scenario• No change in Mars entry or rendezvous orbit compared to non-ISRU scenario

• Influence of ISRU consumable availability or technologies not considered on other systems

– Decisions made on basis of mass/power comparisons. Did not evaluate volume required for ISRU hardware or hydrogen delivered from Earth

Recent Mars Studies with ISRU‒ Considered both atmospheric (CO2, N2, Ar) and soil (H2O) resources based on

increasing knowledge from Mars Odyssey and subsequent missions

1. Mars Design Reference Architecture (DRA) 5.0 – 2007• First study to consider water as a resource; understanding of water on Mars and ISRU

hardware for soil excavation and processing was very preliminary

2. Mars Collaborative Study (HEOMD, STMD, SMD) – 2013• Increased understanding of water on Mars and ISRU hardware needed for soil processing

based on lunar ISRU development and ISRU analog field test experience

3. Mars ISRU Payload for Supersonic Retro Propulsion (SRP) Mission – 2014 • First study to examine volume/packaging of ISRU production options


The Chemistry of Mars ISRU

CO2 + 3 H2 CH3OH + H2O

Methanol

CO + 2 H2 CH3OH

H2O, CH3OH

CH3OH

CO2 + H2 CO + H2O400 - 650 C

H2O

Reverse Water Gas Shift (RWGS)

2 H2O 2 H2 + O2O2, 2 H2

Water Electrolysis (WE)

Methane Reformer

CO + 3 H2 CH4 + H2O250 C

H2O, CH4[Ni catalyst]

2 CO2 2 CO + O2

900 - 1000 C

Zirconia Solid Oxide CO2 Electrolysis (SOE)

O2[Pt catalyst]

CO2 + 4 H2 CH4 + 2 H2O200 - 300 C

Sabatier Catalytic Reactor (SR)

H2O, CH4[Ru catalyst]

[ZnO catalyst]

CO2 + 2 H2 C + 2 H2O450 - 600 C

H2O

Bosch

[Ni, Ru, Fe, or Co catalyst]

Fischer-Tropsch (FT)

n CO + (2n+1) H2 CnH2n+2 + n H2O>150 C

H2O, CnH2n+2[catalyst]

WE to O2

WE to O2

WE to O2

WE to O2

WE to O2

WE to O2

[catalyst]

H2O + CH4 3 H2 + CO 3 H2

Steam Reforming

250 C

50 – 100 atm

Oxygen (O2)

Production Only

Oxygen (O2) &

Methane (CH4)

Production

Other

Hydrocarbon

Fuel Production

Oxygen (O2) &/or

Hydrogen (H2)

Production

2nd Step

CO2 + CH4 2 H2 + 2 CO 2 H2

Dry Reforming

Electrochemical Reduction

CO2 + 2 H2O CH4 + 2 O2[Anode/Cathode] O2, CH4


Mars Design Reference Architecture (DRA) 5.0


Mars ISRU Depends on Resource of Interest

Atmospheric Resource Processing

Strengths

– Atmospheric resources are globally obtainable (no landing site limitations)

– Production of O2 only from carbon dioxide (CO2 ) makes >75% of ascent propellant mass

– Significant research and testing performed on several methods of atmospheric collection, separation, and processing into oxygen and fuel; including life support development

Weaknesses

– Production of methane requires delivery of hydrogen (H2) from Earth which is volume inefficient or water from the Mars soil (below)

– Mars optimized ISRU processing may not use baseline ECLSS technologies

Mars Soil Water Resource Processing (ties to Lunar Ice & Regolith)

Strengths

– Surface material characteristics studied from Mars robotic landers and rovers

– Water (in the form of hydrated minerals) identified globally near the surface

– Lunar regolith excavation and thermal processing techniques can be utilized for Mars

– Low concentrations of water in surface hydrated mineral soil (3%) still provides tremendous mass benefits with minimal planetary protection issues

Weaknesses

– Risk associated with the complexity of the required surface infrastructure must be evaluated. Significant autonomous operations required.

– Local/site dependency on water resource concentration and form

– Concerns from planetary protection and search for life with subsurface material processing


Mars Resource & ISRU Process Options

CO

2 Co

llectio

n &

Co

nd

ition

ing

So

lid O

xid

e C

O2 E

lectro

lysis

Re

ve

rse

Wa

ter G

as S

hift (R

WG

S)

Sa

ba

tier

Bo

sch

Liq

uid

Wa

ter E

lectro

lysis

So

lid O

xid

e H

2 O E

lectro

lysis

Ion

ic L

iqu

id E

lectro

lysis

So

il Pro

ce

ssin

g

So

il Exca

va

tion

& D

eliv

ery

X X

X X X

X X X

X X

X X X X

X X X X

X X

Soil Processing O2, CH4, H2O H2O CH4 **(~6600 kg) X X X

X X X X X

X X X X X

*H2 for water and methane production

**Assumes methane fuel vs hydrogen fuel for propulsion

Process Subsystems/Options

ISRU Resource

Processing OptionsISRU Products

Mars

Resource(s)Earth Supplied

O2, CH4, H2O CO2 & H2OAtmosphere & Soil

Processing

Atmosphere Processing

En

ab

lin

gE

na

blin

g o

r

En

ha

ncin

g

O2

CO2

O2, CH4, H2O

CH4 (~6600 kg)

H2* (~2000 kg)

Four Options for Mars ISRU Ascent Propellant Production:

1. Make oxygen (O2) from Mars atmosphere carbon dioxide (CO2); Bring fuel from Earth

2. Make O2 and fuel/CH4 from Mars atmosphere CO2 and hydrogen (H2) from Earth

3. Make O2 and fuel/CH4 from Mars atmosphere CO2 and water (H2O) from Mars soil

4. Make O2 and H2 from H2O in Mars soil

12

3

1, 2, & 3 Were Evaluated in Mars DRA 5.0


Mars Water Form & Distribution

New Craters Confirm Shallow, Nearly Pure Ice

Newly formed craters exposing water ice (red) are a subset of all new craters (yellow).

Background color is TES dust index. (Adapted from Byrne et al. (2011) Science)

Mid-Latitude Ice-Rich Mantles

Mid- and high-latitude shallow ice

Thought to be dominated by hydrated minerals


Water Abundance and Mars Altitude

0 km altitude>2 km altitude

Water resources between 5-8% near the surface is highly possible for ISRU


Mars Design Reference Architecture (DRA) 5.0

Evaluate Atmosphere Processing Only– Re-evaluate past technologies and system concepts and perform internal trade to determine best

approach for following three ISRU applications:• Propellant production only • EVA and Life support backup only Combined propellant and EVA/life support backup

– Evaluate H2 delivery vs fuel delivery from Earth on Lander volume and mass. Use habitat lander as basis of ‘goodness’

Evaluate Feasibility and Size of Mars Soil/Water Processing System– Make O2 and CH4 with Mars water and atmospheric CO2

– Define Mars soil and water properties at possible exploration sites of interest• Coordinate with Science community• ISRU study assumed 3-8% global concentration and only top few centimeters was

excavated/processed due to Planetary Protection concerns

Evaluate ISRU on Mars Architecture above simple impact on ascent vehicle and surface systems

– Evaluate both circular and highly elliptical orbit impact of ISRU-fuel ascent vehicle on Architecture

ISRU Production Requirements

ISRU to Close Crew & EVA Consumables O2 Water N2/Ar Earth H2 Comment

- Mars Atm. Processing only 1906 133 399 - Closes water thru making water and shortfall of H2 closure

brought from Earth

- Mars Soil Processing only 2146 133 160 - Closes water and shortfall of H2 closure brought from Earth

3586 133 - Closes water and H2 shortfall thru in-situ water only

- Mars Atm. & Soil Processing 1281 2146 133 - Closes water and covers O2 equivalent to H2 closure shortfall

ISRU for All Consumables O2 Water N2/Ar Earth H2 Earth CH4

O2 Only for Propulsion w/ Earth CH4 24891 133 399 6567

O2/CH4 Propellant for Propulsion w/ Earth H2O 24891 133 2069

O2/CH4 Propellant for Propulsion w/ Mars H2O 24266 16788 133

Amount needed per 550 days - crew 6


Soil Excavation & Processing Assumptions & Ground Rules

Soil – Water content in Mars soil 3% by weight; 1000 kg/m3; homogeneous distribution (no dry layer at top)

• Also examined impact of 8% water by weight and 2000 kg/m3

– 6% sulfur in soil by weight

Soil Excavation– Excavation hauler vehicles; level ground

• 8 hr case: assume each excavator can provide the needed 4 batches; continuous operation over

the 8 hrs; recharge at night

• 24 hr case: assume each excavator can provide the needed 6 batches; operate for 12 hrs and

recharge for 12 hrs each day

– Distance traveled: 500 m from site to plant (loaded); 500 m from plant to dump site (loaded);

500 m from dump site to excavation site (unloaded)

– Speed: 0.5 m/s during hauling

– Depth per cut: 4 cm; Total depth: 8 cm

– Dump time to inlet hopper = 5 min.; Time to fill dump from outlet hopper = 5 min.

– Excavation concept assumed: Front-end loader

– Hauler concept assumed: Dump bin

Soil Processing– Water extraction system includes: hopper, auger, extraction reactor (fluidized bed, H2 reduction

reactor model), gas clean-up (packed bed, desulfurization model), and water condenser

– Processing energy provided by separate electrical power system

– Soil processing batch time: 2 hrs

– Inlet and outlet hoper sized to hold 2 days worth of Mars soil for processing for ECLSS cases and 1

day for propellant production

– Heat up power is estimated using basalt model for lunar ISRU

– Processing temperature – heat from soil from input 300K (27C) to processing 600K (327C)


Mars Human Exploration DRA 5.0 ISRU vs Non-ISRU Ascent Results

9,330 kg (CH4)

12,156 kg (CH4)

11280 kg

21,297 kg

54,062 kg

DAV Mass (w/O2 ISRU)

Ascent Stg 2

Ascent Stg 1

ISRU and Power†

Descent stage*

Total

18,540 kg

27,902 kg

5687 kg

27,300 kg

79,428 kg

DAV Mass (no ISRU)

Ascent Stg 2

Ascent Stg 1

Total

Minimal Habitat†

Descent stage*

* Wet mass; does not include EDL System

† Packaging not currently considered

>25 MT savings (>30%)

Lowest Power/Volume: Process atmospheric CO2 into O2; Bring methane (CH4) from Earth

Lowest Mass: Process atmospheric CO2 with Soil processing for H2O into O2 and CH4

Study Results

Atmosphere processing into O2 baselined:

Lowest Risk

Continue evaluation of water on Mars and

soil processing to reduce risk


Mars Collaborative Study


Mars Collaborative Study - 2013

Purpose

Evaluate Mars ISRU technology and system options for propellant production on Mars for a sample return mission

– Oxygen from Mars atmosphere (carbon dioxide)

– Oxygen and Fuel from Mars atmospheric carbon dioxide and water in soil

Examine impact on scale to human mission needs on technology and system selection

– Determine acceptable scale for risk reduction of human mission

– Examine whether technologies can be scaled down to Mars 2020 precursor

Examine state-of-the-art (SOA) of Mars ISRU technologies and potential development cost/risk

– Look for synergism with fuel cell power, life support, and propulsion technology development and system applications

– Look ahead to potential advancements in 5 to 10 years in SOA

Approach

Decouple ISRU plant trade from mission by focusing on production rates

Begin evaluation at major subsystem level

Start with realistic schematics with components and sensor locations identified for major subsystems

– Oxygen (O2) Production from Atmosphere Resources

– Oxygen/Methane (O2/CH4) Production from Atmosphere/Soil Resources

Subsystem down-selection decisions effected by complete system performance

– Need Power and Cryogenic Fluid System support to understand ‘system’ implications

– Need to ensure decisions on interface temp/pressure is consistent at system level


Mars ISRU Trade Tree


Mars Collaborative ISRU Study Results (1)

ISRU Process 0.15 kg/hr 0.35 kg/hr 0.75 kg/hr

kg W kg W kg W

Solid Oxide CO2 Electrolysis 55 1444 126 3295 264 6976

Reverse Water Gas Shift w/Water Electrolysis 57 1328 101 3084 189 6770

Solid Oxide CO2/H2O Electrolysis w/Sabatier &

Mars Soil56 1631 90 3788 128 8110

Sabatier w/Water Electrolysis & Mars Soil 64 1744 95 3793 149 7775

Note:

1. Mass of rover for soil excavation is not shown since it uses the sample fetch rover once the samples have been collected

2. Liquefaction mass and power not included since they will be similar for all options with the same production rate

ISRU Subystem/System

Attributes

CO

2 Fre

ezer

Rapid

Cycle

Adsorp

tion P

um

p

SO

E

RW

GS

/WE

Sabatie

r/WE

SO

E w

Sabatie

r

Sabatie

r/WE

; Soil

Pro

cessin

g

SO

E w

Sabatie

r;

Soil P

rocessin

g

Complexity G M G P G G P P

Number of active components 6 15 8 20 11 10 21 20

Rapid Startup/Shutdown M G P G G P G P

Commonality with Life Support M G P M G M G M

Commonality with Fuel Cell Power G M M

Rankings are relative: G=Good, P = Poor, M = Medium


Mars Collaborative ISRU Study Results (2)

Mars Atmosphere CO2 Collection‒ Microchannel Rapid-Cycle CO2 Collection technology preferred over CO2 Freezer‒ CO2 Freezer more likely scalable down to Mars 2020 mission

O2 Production from Mars Atmosphere− Both Solid Oxide CO2 Electrolysis (SOCE) and Microchannel Reverse Water Gas Shift with Water

Electrolysis (RWGS/WE) have comparable mass and power− SOCE is slightly lighter and simpler but may be more risky. Less synergistic with life support but

more synergistic with solid oxide fuel cell; Best packaging for Mars 2020 ISRU demonstration− All microchannel design (CO2 collection, RWGS reactor, water vapor separation) may be best for

packaging and scalability to human mission; Also not as effected by day/night operation cycle from solar power.

O2 and CH4 Production from Mars Atmosphere and Soil− Both Solid Oxide CO2 Electrolysis (SOCE) with Sabatier and Microchannel Sabatier with Water

Electrolysis have comparable mass and power− Mars soil excavator or processor appears to be able to fit on sample cache rover; power system

will need to be supplemented − Similar pros/cons for SOCE vs microchannel as O2 Production only− Ionic liquid concept shows tremendous promise but is still too low in TRL to select

Key Findings on ISRU Concept Discriminators− When considering only mass and power of the ISRU system concept, atmosphere only vs

atmosphere/soil are comparable to each other− Advanced technologies such as microchannel reactors, heat exchangers, water/gas separators,

and carbon dioxide adsorption pumps provide significant mass/volume improvement over conventional technologies as production rates increase

− Oxygen only production from the Mars atmosphere is less synergistic with life support systems than oxygen/fuel production since these ISRU processes produce carbon monoxide


Mars ISRU Demo Payload for Supersonic Retro Propulsion (SRP)

Mission


Mars ISRU Demo Payload for Supersonic Retro Propulsion (SRP) Mission

Assumptions for ISRU payload definition:– Mass of (TBR) 2MT maximum

– Deck height for payload ~ 1 meter height

above surface; horizontal landing

– CG roughly centered (soft requirement)

– Cylindrical payload volume: 2 m dia. X 4 m long

ISRU payload study purpose:a. Determine highest production rate/scale possible within payload mass/volume limits

• Define maximum amount of power to ISRU payload – use solar arrays

• Define/utilize remaining payload for ISRU and storage.

b. Provide 3-D packaging concept for

atmosphere processing and soil

processing demonstrations

c. Determine payload applicability to human

scale mission

ISRU Demo Payload Options:– Atmosphere processing for oxygen (O2)

production alone with O2 storage

– Soil processing for water (H2O) with

O2 storage

– Combined Atmosphere/Soil Processing

for O2 and Methane (CH4) production and

storage


Mars ISRU SRP Payload Study Analysis Overview

ISRU Demo mass, power, and volume are first order estimates• All items required for successful operation included in payload. No sharing of SRP

subsystems/hardware

• Technologies & processes were selected to bound the wide scope of possible process

configurations.

• No day/night operation (startup/shutdown impacts) or power impacts analyzed. Just assumed

constant production rate for 8 hours per Mars day (sol).

• Components requiring heat rejection were identified for start of thermal management/packaging

• Packaging based on subsystem connectivity

• Center of Gravity (c.g) management not considered in ISRU demo packaging at this time.

Notional landing location/latitude and time of year selected that was not based on

an actual mission concept (not available)• 15 deg. north latitude selected. Considered reasonable location for landing (low MOLA)

• Landing at Ls 180 maximizes solar power generation capability at landing location; assume

landing 50 days prior for 100 day mission

Power/packaging evaluation performed for notional landing location • Packaging of 5.5 to 6 m diameter array possible based on notional payload bay and use of

ATK UtraFlex solar array design parameters

• Equates to rough estimate of 6.5 to 7.5 KWe power generation possible

‒ Assumed 6.5 KWe for 8 hours per sol as reasonably conservative estimate


Mars ISRU Demo SRP Payload Study Options

Mars Atmosphere Processing (O2 only)• Electrostatic precipitator w/ regenerative HEPA filter

• CO2 collection (freezing)

• CO2 processing: Solid Oxide Electrolysis

• CO/CO2 separation and recycling to increase

performance

• O2 liquefaction

• O2 storage (100 days)

Mars Atm/Soil Processing (O2/CH4)• Electrostatic precipitator w/ regenerative.

HEPA filter

• CO2 collection (freezing)

• CO2 processing: Sabatier Reactor

• Rover/Excavation

• Soil processing reactor (up to 450 C)

• Water separation/cleanup module

• Water electrolysis (Cathode Feed PEM)

• O2 & CH4 product dryer

• O2 & CH4 liquefaction & Storage (reduced)


Mars ISRU Demo SRP Payload Study Results

Combined Atm/Soil ISRU Demo

O2 Production rate: 0.48 kg/hr; Mass (kg) Power (KW) CH4: 0.12 kg/hr

Filtration 1.3 0.00025

CO2 Collection/Freezer 43 0.574

Sabatier Microchannel Reactor 1 0.082

Rover Excavator** 170

Soil Processor & Water Separation 193 1.7

Water Capture/Temp Storage 3.7 0.5

Water Electrolysis (2) 40 2.8

O2 and CH4 Dryers 5 0.098

O2 Liquefaction and Storage 72 0.7

CH4 Liquefaction and Storage 58 0.42

Secondary Structure (15%) 88.1

Solar Arrays (2) 45

Power conditioning/batteries* TBD TBD

Thermal Management/Radiators TBD TBD

Total 720.1 6.9

Mars Soil ISRU Demo

O2 Production rate: 0.48 kg/hr Mass (kg) Power (KW)

Rover Excavator** 170

Soil Processor & Water Cleanup 193 3.1

Water Electrolysis (2) 40 2.8

O2 Dryer 4.1 0.064



Solar Arrays (2) 45



Total 596.0 6.66

*Mass and power available for batteries

**Rover not optimized for soil excavation or production rate

Rover not included

Rover oversized for

mission

Human mission would include 3 units

(each slightly scaled up)

Mars Atm ISRU Demo

O2 Production rate: 0.45 kg/hr Mass (kg) Power (KW)

Filtration 1.23 0.00025

CO2 Collection/Freezer 173 2.23

SOE Processor 5.6 3.7

SOE Recirculation system 34.6 0.187



Solar Arrays (2) 45



Total 372.1 6.72

Atm Soil Combined

Mass (kg) 246.59 272.67 330.05

Power (KW) 6.12 5.96 5.75

ISRU Plant Only


Water/Volatiles Released from Mars Soil(SAM instrument: Rocknest sample)

1 2

Region 1: <300 C

40-50% of the water released

Minimal release of HCl or H2S

Region 2: <450 C

>80% of the water released

CO2 and O2 released from decomposition

of perchlorates and oxidation of organic

material

Some release of HCl or H2S, but before

significant amounts are release at higher

temperatures

Predicted Volatile Release Based on Lab Experiments

CO2 released by

1. Absorbed atmosphere <200C

2. Oxidation of organic material >200 C

3. Thermal decomposition of carbonates >450 C

O2 released by

1. Dehydroxylation of clays <350 C

2. Decomposition of non-metal and metal oxides >500 C

CH3Cl and CH2Cl2 released by

1. Decomposition of Mg(ClO4)2 perchlorate >200C


Mars ISRU State of the Art


Mars ISRU Propellant Production

Needs Propellant production for human mission ascent (Mars DRA 5.0)

– For O2 only: 2.2 to 3.5 kg/hr O2; 480 days or 300 days– For O2/CH4:

• 0.55 to 0.88 kg/hr CH4• 1.2 to 2.0 kg/hr H2O; (41 to 66 kg/hr soil @ 3% H2O by mass)

Propellant production for Mars Sample Return– 0.35 to 0.5 kg/hr O2; 420 to 500 days (multiple studies)– 0.75 to 1.5 kg/hr O2; 35 or 137 days (Mars Collaborative Study 4-2012)

Propellant production for Mars ISRU Demo– 0.02 kg/hr O2; 50 operations (Mars 2020 AO requirement)– 0.00004 kg/hr O2; 10 operations (MIP demo on Mars 2001 Surveyor)

Demonstrated Mars ISRU Testbeds (late ’90s early ‘00s):

– LMA/JSC Sabatier/Water Electrolysis: 0.02 kg/hr O2; 0.01 kg/hr CH4– KSC RWGS/Water Electrolysis 0.087 kg/hr O2– Pioneer Astronautics (SWE & RWGS): 0.02 kg/hr O2; 0.01 kg/hr CH4

(IMISPPS): 0.031 kg/hr O2, 0.0088 kg/hr CH4

Atmosphere Processing: MARCO POLO (Individual subsystems)– CO2 Collection: 0.088 kg/hr CO2– CO2 Processing: 0.066 kg/hr of O2; 0.033 kg/hr of CH4; 0.071 kg/hr of H2O– Water Processing: 0.52 kg/hr H2O; 0.46 kg/hr O2

Soil Processing:– Lunar H2 Reduction - ROxygen Reactor: 5 to 10 kg/hr soil: – Lunar H2 Reduction - PILOT Reactor: 4.5 to 6 kg/hr soil:– Mars Soil Auger - MISME: 0.18 to 0.2 kg/hr soil– Mars Soil Reactor-Pioneer Ast. Hot CO2 4 kg/hr soil per batch

Larg

e G

ap

betw

een

Need

s a

nd

Dem

on

str

ate

d


Past/Recent Mars ISRU Technology Development

CO2 Collection & Separation

Mars atmosphere adsorption pump (JPL, ARC, LMA, JSC)

Microchannel adsorption pump (PNNL, SBIR)

Mars atmosphere solidification pump (LMA, SBIR, NASA)

CO2 Processing

CO2 electrolysis & low pressure dissociation

(NASA, Univ. of Arizona, Old Dominion, Industry, SBIRs)

Reverse Water Gas Shift (KSC, PNNL, SBIRs)

Sabatier reactors (NASA, Industry, SBIRs)

Methane reformer (JPL, SBIRs)

Hydrocarbon fuel reactors - methanol, toluene, ethylene, etc. (SBIRs)

Microchannel reactors/heat exchangers (PNNL, SBIRs)

Water Processing

Water electrolysis/decomposition (NASA, Industry, SBIRs)

Water cleanup for lunar soil processing (KSC, SBIRs)

Water vapor/gas cleanup for lunar soil processing (NASA, SBIRs)

Soil Processing

H2 Reduction of regolith reactors (NASA, LMA)

Lunar volatile extraction (NASA, Industry)

Mars soil processing (JSC, SBIRs)


Past/Recent Mars ISRU System Development

Mars Atmosphere Processing

1st Gen Sabatier/Water Electrolysis (SWE) breadboard under ambient & Mars environment

testing (NASA, Lockheed Martin)

1st Generation Reverse Water Gas Shift with and w/o Fuel production

(NASA, Pioneer Astronautics)

2nd Gen MARCO POLO atmosphere processing (JSC, KSC)

Lunar/Mars Soil Processing

1st Gen H2 Reduction from Regolith Systems (NASA, LMA)

2nd Gen MARCO POLO soil processing system (JSC, KSC) – design only

Sabatier/Water Electrolysis w/

CO2 Absorption (LMA & JSC)

[Tested under simulate Mars

surface conditions]

ROxygen H2 Reduction

Water Electrolysis

Cratos Excavator

PILOT H2 Reduction

Water Electrolysis

Bucketdrum Excavator

MARCO POLO

• Soil dryer with regolith

delivery and avionics

• Water cleanup and

storage

CO2 Electrolysis (GRC)

[Tested under

conference conditions]

Combined Sabatier/

RWGS/Water Electrolysis

(Pioneer Ast.)

Reverse Water Gas Shift/ Water

Electrolysis (KSC & Pioneer

Astrobotics)


Current ISRU Activities

SBIR Technologies

Mars dust filtration

CO2 collection and pressurization

CO2 electrolysis

Microchannel Sabatier reactors

Mars 2020 ISRU Demo

Make 0.02 kg/hr O2; <600 W-hrs; 50 sols of operation

Water/Volatile Characterization/Prospecting

Resource Prospector Mission – RESOLVE payload

RESOLVE• Measure H2O . 0.5% wt. down to 1 m• Measure: H2, CO, NH3, CH4, H2S• Nom. Mission Life = 10+ Cores• Mass = 100 kg• Dimensions : 68.5 x 112 x 1200 cm• Ave. Power; 200 W

Advanced Exploration Systems (AES)

Trash to Supply Gas; Steam Reforming/O2 Combustion

Mars Architecture, Systems, & Technologies for Exploration & Resources (MASTER)– Demonstrate integration and operation of ISRU, Power, and Life Support systems around liquid

oxygen and methane under different mission architectures

– Proposed AES new start in FY15


Results/Conclusions

Using Mars atmosphere carbon dioxide (CO2) alone is the lowest risk

‒ CO2 is available everywhere on Mars and no ISRU hardware needs to be deployed

‒ Multiple options exist to extract oxygen (O2) from CO2

‒ Least amount of hardware and volume of all ISRU options

While lower in mass, carrying hydrogen (H2) from Earth to make O2/methane (CH4) is

volumetrically and technically difficult

– H2 is <1/3 the mass but 3 times the volume compared to CH4 brought from Earth

Using both Mars atm. CO2 and water (H2O) from the Mars soil is the lowest mass.

‒ Extra hardware for soil excavation and processing significantly less than mass of ascent

fuel brought from Earth

‒ Power needed for either approach is similar enough not to impact power system greatly

‒ Mass benefit increases and power difference decreases with increase in water content

in soil above 3% by mass.

Using both Mars atmosphere CO2 and H2O from the Mars soil provides the greatest

architecture/mission benefits.

‒ 100% of O2/fuel produced on Mars• Allows for Mars ascent, surface hoppers, and production of fuel cell reactants for surface mobility

‒ Water can be used for life support, plant growth, and radiation shielding

‒ Processes and technologies are similar to lunar water/O2 extraction from regolith and

NEA mining.• Proving Ground activities on lunar surface, NEAs, and Phobos will reduce risk


Backup


How Propellant Production Enables Future Moon & Mars Missions

11.3 kg in LEO

8.4 kg used for TMI

propulsion

2.9 kg prior to Mars EDL

1 kg propellant on Mars

1.9 kg used for EDL

Earth Orbit

Mars

Estimates based on Aerocapture at Mars

226 kg on Earth

Every 1 kg of propellant made on Mars saves 7.5 to 11.3 kg in LEO 25,000 kg mass savings from propellant production on Mars for ascent = 187,500 to 282,500 kg launched into LEO


Why Methane Fuel?

Simplicity of ISRU Processing– Single step process for methane.

• Two or more steps for most other hydrocarbon fuels

– High processes conversion:

• >99% methane product from CO2 in single pass (recycle H2)

• Other fuels (such as Fischer Tropsch) have wide band of hydrocarbons produced; must

separate and recycle (increase complexity), or accept (decrease in engine performance)

Higher propulsion efficiency– Pros: Higher Isp than most other hydrocarbons

High ox/fuel (O/F) mixture ratio. (Max. benefit for O2 only ISRU)

Clean burning; no coking

– Cons: Methane is lower density than other hydrocarbons

High H-to-C ratio (Min. benefit for Earth provided H2 ISRU options)

Higher compatibility with liquid oxygen– Same technology, insulation, cryocoolers, and tanks used for CH4 as with LO2

– Thermal compatibility of lines and engine/thruster thermal management

Overall, choice of methane fuel is an overall balance of performance, storage,

compatibility, and production

NTO/MMH

Press-fedLO2/Hydrazine

Press-fed

LO2/Methane

Press-fed

LO2/Propane

Press-fed

LO2/Methanol

Press-fed

LO2/Ethanol

Press-fed

LO2/Ethylene

Press-fed

LO2/Kerosine

Press-fed

LO2/LH2

Press-fed

LO2/LH2

Pump-fed

Isp 328 365 362 357 335 340 364 352 441 454

MR 1.9 1.0 3.5 3.25 1.5 2 2.75 3.0 5.25 6.0

Fuel Density (kg/m3) 880 1020 422 500-580 792 789 568 810 71 71

Fuel B.P (K) 360 387 111.7 230.9 337.8 351.5 169.5 20.3 20.3

Based on Chamber Pressure (Pc) = 500 psi; Area Ratio (AR)=150:1; Efficiency = 93%

Documents

Mars ISRU for Production of Mission Critical Consumables ... · Mars ISRU for Production of Mission Critical Consumables – Options, Recent Studies, and Current State of the Art